Heat transfer apparatus and heat transfer system for masonry heater

ABSTRACT

An apparatus and system for efficiently and safely transferring heat from a masonry heater to an external heating device using coil pipes and a liquid circulation pump. Circulation of a heat transfer liquid in the apparatus and system is controlled based on the measured temperature of the heat transfer liquid in the coil pipe on a return side of the masonry heater. Two additional sensors near the external heating device are used to control the flow rate of the circulation of the heat transfer liquid in the apparatus and system, thereby controlling the amount of heat actually transferred to the external heating device.

FIELD OF INVENTION

The present invention relates to apparatus and systems for efficientlytransferring heat from a masonry heater to other devices separate fromthe masonry heater.

BACKGROUND OF THE INVENTION

The following description includes information that may be useful inunderstanding the present invention. It is not an admission that any ofthe information provided herein is prior art or relevant to thepresently claimed invention, or that any publication specifically orimplicitly referenced is prior art.

Masonry heaters are devices used to heat the interior of a building byabsorbing the intense heat of a fire into masonry material and graduallyreleasing the heat over a period of hours. Although the radiant heatreleased by the masonry heater is low compared to other heaters, thetemperatures inside masonry heaters can reach in excess of 2000° F.—farmore than conventional metal furnaces can handle. Efficiently andeffectively capturing and transferring the intense heat from masonryheaters to other devices would drastically reduce the energy required toheat other areas and/or fluids. However, previous attempts to captureand transfer heat from masonry heaters have been less successful thandesired.

DETAILED DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in the referenced figures. Theembodiments and figures disclosed herein are intended to be illustrativerather than restrictive.

FIG. 1 illustrates a prior art masonry heater.

FIG. 2A illustrates a front view of a masonry heater with a coil pipeinstalled horizontally as part of the heat transfer apparatus.

FIG. 2B illustrates a side view of the masonry heater of FIG. 2A.

FIG. 2C illustrates a front view of a masonry heater with coil pipesinstalled vertically as parts of the heat transfer apparatus.

FIG. 2D illustrates a side view of the masonry heater of FIG. 2C.

FIG. 3 illustrates a single coil pipe.

FIG. 4 illustrates a schematic view of a heat transfer apparatus andheat transfer system utilizing the present invention.

FIG. 5 illustrates a perspective view of FIGS. 2A-2B.

FIG. 6 illustrates a perspective view of FIGS. 2C-2D.

FIG. 7A illustrates the back of a masonry heater of FIGS. 2A-2B.

FIG. 7B illustrates the back of a masonry heater of FIGS. 2C-2D.

FIG. 8 illustrates a schematic view of the supply side of a heattransfer apparatus or heat transfer system.

FIG. 9 illustrates a schematic view of the return side of a heattransfer apparatus or heat transfer system.

FIG. 10 illustrates a perspective view of the supply and return sides ofa heat transfer apparatus or heat transfer system.

FIG. 11 illustrates a side view of the return side of a heat transferapparatus or heat transfer system.

FIG. 12 illustrates an exploded view of a temperature sensor, aT-junction, and a coil pipe shown assembled in FIG. 13.

FIG. 13 illustrates a temperature sensor disposed in the coil pipewithin the firebox of a masonry heater.

FIG. 14 illustrates the electrical connections of sensors to acontroller that is connected to a liquid circulation pump.

FIG. 15 illustrates an external heating device (boiler) connected to aheat transfer apparatus.

FIG. 16A illustrates a liquid heater and thermal dump apparatusconnected to a heat transfer apparatus.

FIG. 16B illustrates a control diagram for a single radiant heat zone ina thermal dump apparatus.

FIG. 16C illustrates a control diagram for more than one radiant heatzones in a thermal dump apparatus.

FIG. 17 illustrates a thermal dump apparatus and external heating devicein a heat transfer system.

FIG. 18 illustrates an external heating device connected to a heattransfer apparatus.

FIG. 19 illustrates two liquid circulation pumps and a low-loss headerconnected to a heat transfer apparatus.

FIG. 20 illustrates two liquid heaters connected to a heat transferapparatus.

FIG. 21A illustrates a flow chart for controlling a liquid circulationpump.

FIG. 21B illustrates a flow chart for controlling a heat transferred toa thermal dump zone.

FIG. 22 illustrates a plurality of other heat sources connected to themasonry heater and external heating device in a heat transfer system.

DETAILED DESCRIPTION OF THE INVENTION

One skilled in the art will recognize many methods, systems, andmaterials similar or equivalent to those described herein. The presentinvention is in no way limited to the methods, systems, and materialsdescribed.

Embodiments of the present invention relate to apparatuses and systemsfor capturing and transferring heat from a masonry heater to a deviceexternal to the masonry heater. It is desirable to capture the heat froma masonry heater to increase the overall efficiency of a household andreduce the cost of heating water and air, for example, during coldwinter months. Embodiments of the present invention significantlyimprove the amount of energy captured and transferred from a masonryheater compared to previously known designs.

Referring to FIG. 1, masonry heater 100 is composed primarily of amasonry material, such as stone, brick or tile, instead of metal. Fuel,usually wood, is burned in the firebox 104 of the masonry heater 100where temperatures may exceed 2000° F., causing combustion of nearly allgases in the firebox 104. In contrast, metal stoves are designed to ventgases to prevent the gases from melting or damaging the metal housing.Once the fuel is lit in the firebox 104, the masonry absorbs and slowlyradiates the heat outward over a period of several hours at a relativelyconstant rate. A secondary burn chamber 102 (“oven”) is typicallylocated above the firebox 104 and fitted with a door for cooking,although the secondary burn chamber 102 is not necessary for a fullyfunctional masonry heater 100. Masonry heater 100 may have varyingshapes, including cylindrical, square, rectangular or tapered designs.Masonry heater 100 may also have smoke channels located between thefirebox 104 and the chimney to further absorb and evenly distributeheat. As those of ordinary skill in the art will recognize, masonryheater 100 may come in varying shapes and sizes, and have additionaldesign features not illustrated in FIG. 1 without departing from thedescription and illustrations contained herein.

FIGS. 2A and 2B illustrate an embodiment of a heat transfer apparatuswhere lengths of coil pipes 200 are disposed in the firebox 104 of amasonry heater 100. In this embodiment, the coil pipes 200 are orientedin a substantially horizontal manner near or at the top of the firebox104. As shown in FIG. 2A, the coil pipes 200 extend across a substantialportion of the firebox 104 to increase the area of coil pipes 200 thatare directly exposed to heat. The coil pipe 200 may be located fartherdown in the firebox 104 to the heat source; however, this may decreasethe space available for placement of fuel and may not significantlyincrease performance of the heat transfer apparatus. FIG. 2B illustratesa side view of the horizontal orientation of the coil pipe, where thecoil pipes 200 extend into the firebox 104, and a temperature sensor islocated within the firebox 104 in a liquid return path of the coilpipes, as discussed later in more detail. Alternatively, the coil pipes200 may extend from a side wall or other wall of the masonry heater 100,as long as heat from the firebox 104 intersects with the coil pipe 200in a direction substantially orthogonal to the direction in which thecoil pipes 200 extend. In FIGS. 2A and 2B, two coil pipes 200 areillustrated at the top of the firebox 104 to maximize the amount of heatand power captured and transferred from the firebox 104, however, asingle coil pipe 200 or more than two coil pipes 200 may be installed inthe firebox 104 without departing from the scope of the heat transferapparatus or heat transfer system described herein.

FIGS. 2C and 2D illustrate an embodiment of a heat transfer apparatuswhere coil pipes 200 are oriented in a vertical manner in the firebox104. Typically, the coil pipes 200 are installed adjacent to the sidesof the firebox 104 in this configuration to allow access to the coilpipes 200 for maintenance, and to maximize the available space forstacking wood or other fuel. In this configuration, liquid enters thefirebox 104 at the bottom end of the coil pipe 200 and exits the firebox104 at the top end of the coil pipe, which promotes evacuation of anyaccumulation of gases in the heat transfer apparatus, as describedlater. As illustrated in FIG. 2D, a first temperature sensor 202 shouldbe located within the firebox 104 in a liquid return path of the coilpipe 200 at the top end of the coil pipe. It is desirable that the firsttemperature sensor 202 extends through wall 106 and far enough into thefirebox 104 to obtain an accurate measurement of the liquid at itshottest point, before the liquid exits the firebox 104 and begins tocool. A vertical orientation may be preferable to the substantiallyhorizontal orientation where access to the interior of a masonry heater100 is limited, or where such an orientation is preferable due to thetype or style of masonry heater 100, such as a double bell masonryheater 100. It is important to orient the coils to permit access to thecoil pipes 200 for maintenance and repair purposes. Although two coilpipes 200 are illustrated in FIG. 2C, any number of coil pipes 200 maybe oriented in a vertical manner within the firebox 104 to achieve thedesired amount of heat transfer.

The coil pipe 200 orientations shown in FIGS. 2A-2D promote maximumenergy capture and transfer, but other orientations may achieve similarresults. For example, two coil pipes 200 could be oriented in a verticaldirection along a single wall of the masonry heater 100. Coil pipes 200may also be located in other portions of the masonry heater 100, such asin a downdraft channel or in a secondary heating chamber 102 such as theoven, but such placements may not capture the same amount of heat andpower per coil pipe 200 as coil pipes 200 placed in the firebox 104 ofthe masonry heater 100.

FIG. 3 shows a typical coil pipe 200 that is installed in the firebox104 of a masonry heater 100, such as the firebox 104 illustrated inFIGS. 2A-2D. Water is typically used as the liquid in the coil pipes,but other liquids such as glycol may be used to achieve similar effects.Water is used to achieve uniformity in the masonry heater 100 (primary)side and the external heating device 208 (secondary) side. In a typicalinstallation, the length that the coil pipe 200 extends into the firebox104 is approximately 23.5 inches, while the coiled part of the pipe isapproximately 18 inches of that length. The width of the coil pipe 200in a horizontal direction of the masonry heater 100 is approximately 18inches. The diameter of the coil pipe 200 is approximately 0.75 inches.The total length of a coil pipe 200 typically installed in a heattransfer apparatus is approximately 9 feet, which ensures that theliquid in the coil pipe 200 will have sufficient exposure to heat in thefirebox 104 to maximize the temperature of the liquid without vaporizingthe liquid. Where two coil pipes 200 are installed in the firebox 104 ina horizontal manner, as illustrated in FIGS. 2A and 2B, the total lengthof coil pipes 200 exposed to the heat of the firebox 104 is 18 feet.

The length of the coil pipe 200 exposed to heat is a critical factor tothe overall efficiency and safety of the heat transfer apparatus. If thelength of exposed coil pipe 200 is too short, the amount of powerextracted from the masonry heater 100 is not maximized. On the otherhand, if the length of exposed coil pipe 200 in the firebox 104 is toolong, the liquid in the coil pipe 200 will vaporize which may damage theheat transfer apparatus or cause injury to the operator. The dimensionsof the coil pipes 200 require only a small volume of liquid to achievesafe and efficient transfer of heat. Typically, only about one-quarterto one-third of a gallon of liquid is used in a two pipe coil system. Inthe event of failure due to power outage, a Temperature and Pressurerelief valve (TxP valve 506) will dump liquid from the heat transferapparatus through the drain 508 if the temperature and/or pressure ofthe liquid becomes too high, but it is preferable that only a smallvolume of liquid is contained in the system to prevent injury to personsor damage to the system. Stainless steel pipes are preferred for thecoil pipes, which are fairly inexpensive, yet can withstand 250° F.temperatures and 10,000 pounds of pressure per square inch. Othermaterials may be used for the coil pipes, as long as the materials cansimilarly withstand high temperatures and pressures.

FIG. 4 depicts a schematic view of a portion of a heat transferapparatus and a portion of a heat transfer system. Sensor S1 is thefirst temperature sensor 202 which extends within the firebox 104 in thecoil pipe, and is connected to an input of a controller 210. A liquidcirculation pump 212 circulates heated liquid from the coil pipe 200 inthe masonry heater 100 to the external heating device 208 when thecontroller 210 detects that the temperature measured by the sensor S1 isequal to or greater than a predetermined temperature threshold. Thepredetermined temperature threshold should be approximately 150° F. Thesystem will enter thermal runaway if the predetermined temperaturethreshold is set too high above 150° F. Conversely, if the predeterminedtemperature threshold is set below 150° F. by a significant amount, theliquid circulation pump 212 will continuously circulate the liquid afterfiring, needlessly wasting energy and increasing the cost of operation.

Temperature sensor S2 (204), which is connected to an input of thecontroller 210, detects a temperature of the liquid flowing to theexternal heating device 208 from the masonry heater 100 (on the returnside 216 of the masonry heater 100). Temperature sensor S3 (206), whichis also connected to an input of the controller 210, detects atemperature of liquid returning from the external heating device 208 tothe masonry heater 100 (on the supply side 214 of the masonry heater100). When the temperature measured by the sensor S1 exceeds thetemperature threshold, the controller 210 directs the liquid circulationpump 212 to begin circulating the liquid and controls the flow rate ofthe liquid circulation pump 212 based on a difference between thetemperatures measured by the sensors S2 and S3. The flow rate isadjusted to maintain a specified difference in temperature betweensensors S2 and S3. For example, if the difference in temperature betweensensors S2 and S3 is greater than the specified difference, indicatingthat the amount of heat being transferred to the external heating device208 is too large, the controller 210 will increase the flow rate of theliquid circulation pump 212 to reduce the amount of heat transferred tothe external heating device 208. If the measured difference intemperature is less than the specified difference, indicating that theamount of heat transferred to the external heating device 208 is toosmall, the controller 210 will decrease the flow rate of the liquidcirculation pump 212 to increase the amount of heat transferred to theexternal heating device 208. If the difference in temperature is withina specified range of the specified temperature, the controller 210 willmaintain the current flow rate of the liquid circulation pump 212. Thespecified temperature differential should be around 20° F. The specifiedrange and specified temperature settings in the controller 210 may beadjusted by a user to accommodate the number of external heating device208s and the type of external heating devices 208 connected to the heattransfer apparatus. Once the fuel in the masonry heater 100 isexhausted, the temperature of the liquid in the coil pipes 200 willlower and eventually the controller 210 will stop circulation of theliquid. The controller 210 may be a Johnson Controls A419ABC-1 (110 VoltAC), by way of non-limiting example. The operation of the controller 210and the liquid circulation device are discussed in greater detail later.

FIG. 5 illustrates a perspective view of two horizontally oriented coilpipes 200 connected together as in the embodiment of FIGS. 2A and 2B.When the liquid circulation pump 212 is off, the masonry heater 100heats the liquid to a predetermined temperature, as detected by thefirst temperature sensor 202, at which point the controller 210 turnsthe liquid circulation pump 212 on and begins circulate the liquid tothe external heating device 208. The tip of the first temperature sensor202 should extend well into the masonry heater 100 to ensure that aproper temperature reading of the liquid returning from the masonryheater 100 is taken. If the first temperature sensor 202 does notproperly extend into the firebox 104, the heat transfer system may enterthermal runaway potentially damaging the system. The first temperaturesensor 202 is typically installed in a T-junction at an elbow joint andextending through aperture D at the return side 216 of the masonryheater 100 for ease of installation and maintenance. Alternatively, thefirst temperature sensor 202 may be installed in the liquid return pathof the other coil pipe 200 through aperture C without affecting theperformance of the heat transfer apparatus, but such an installation isnot as easily implemented.

When the liquid circulation pump 212 is in a circulation mode, the heattransfer liquid enters the masonry heater 100 on supply side 216 throughcoil pipes 200 extending through apertures A and B. The heated liquid isthen transferred from inside the masonry heater 100 through coil pipes200 extending through apertures C and D, and back to the return side216, where the heated liquid then flows back to the liquid circulationpump 212. As discussed later, an auto-vent valve 502 and TxP valve 506may be located on the return side 216.

FIG. 6 shows a perspective view of two vertically oriented coil pipes200 connected together as in the embodiment of FIGS. 2C and 2D. Thesystem works essentially the same as the embodiment shown in FIG. 5,except that the supply side 214 is located on the bottom side of themasonry heater 100, rather than on a left or right side of the masonryheater 100. In this configuration, it is desirable to have the tip ofthe first temperature sensor 202 extend in a liquid return path of thecoil pipe 200 closest to the liquid circulation pump 212. As with theconfiguration of FIG. 5, the first temperature sensor 202 is preferablyinstalled in the elbow joint on the return side 216 of the masonryheater 100.

In FIGS. 7A and 7B, the back of the masonry heater 100 is illustrated.FIG. 7A corresponds to the coil pipe 200 configuration of FIG. 5, wherethe coil pipes 200 are substantially horizontally oriented. When thecoil pipes 200 are substantially horizontally oriented, the supply side214 of the coil should be located sufficiently lower than the returnside 216 of the coil pipes 200 to ensure that any gas trapped in thecoil pipe 200 rises to the return side 216, and is purged by theauto-vent valve 502, as described later. The rise y₁ of the coil pipes200 in the vertical direction is not particularly limited, but the risein typical installations is around 2 inches to ensure proper evacuationof gas from the lines. FIG. 7B corresponds to the coil pipe 200configuration of FIG. 6, where the coil pipes 200 are verticallyoriented.

FIG. 8 illustrates the supply side 214 of a heat transfer apparatus andsystem according to either of FIG. 5 or FIG. 6. As discussed earlier,when the liquid circulation pump 212 is operating, liquid is pumped froman external heating device 208 back toward the masonry heater 100 whereit passes through a check valve 510. Check valve 510 allows the liquidto flow in only one direction toward the masonry heater 100. Installinga check valve 510 in this way serves two functions: first, it ensures afaster response time when the masonry heater 100 is heating up bypreventing the expanding liquid from back-flowing to the supply side 214of the masonry heater 100. Second, on failure, the check valve 510allows in a small amount of cooler water to cool the coil pipe. A swingcheck valve 510 is preferred as check valve 510, but a ball check valve510, lift check valve 510, diaphragm check valve 510 or other stylecheck valve 510 may be used instead. A check valve 510 should beselected having a size sufficient to support the flow of liquid throughthe system, and that can also withstand the temperature of the liquid.The liquid flows from the check valve 510 to the supply side 214 of thecoil pipe 200 where the liquid enters the coil pipe 200 and the masonryheater 100. FIG. 8 illustrates that the supply side 214 feeds two coilpipes, however, the supply side 214 may feed only one coil pipe 200 ormore than two coil pipes 200 without departing from the scope of theheat transfer apparatus and system described herein.

FIG. 9 illustrates the return side 216 of a heat transfer apparatus orheat transfer system according to either of FIG. 5 and FIG. 6. When theliquid circulation pump 212 is operating, liquid is pumped from the coilpipes 200 inside of the masonry heater 100 toward the external heatingdevice 208. The return side 216 may also include a hi-point auto-ventvalve 502 and/or TxP valve 506. The auto-vent valve 502 automaticallypurges any gas stuck in the lines from the system. The auto-vent valve502 may be a Maid-O'-Mist® 670, by way of non-limiting example. A ballvalve 504 may be located between the return side 216 of the coil pipe200 and the auto-vent valve 502 to facilitate the replacement of theauto-vent valve 502 without draining liquid from the pipes. The TxPvalve 506 purges liquid from the system if the temperature of the liquidexceeds a predetermined temperature or if the pressure in the linesexceeds a predetermined pressure. It is important to match thetemperature and/or pressure characteristics of the TxP valve 506 withthe characteristics of the external heating device 208. For example,when the heat transfer system transfers heat to a domestic water systemhaving a hot water heater, if the pressure in the lines exceeds 75pounds per square inch (PSI), the TxP valve 506 will drain liquid fromthe system until the pressure is reduced to less than 75 PSI. When theheat transfer system transfers heat to a hydronic heating system, whereliquid is circulated through tubing to radiate heat, the TxP valve 506should drain liquid from the system if the pressure exceeds 30 PSI. TheTxP valve 506 purges liquid from the system into a drain line so thatthe liquid will be cleanly and safely removed. As a non-limitingexample, the TxP valve 506 may be a Zurn® P10000HXL-150C when theexternal heating device 208 is a hot-water heater. When the externalheating device 208 is a boiler, an Apollo 10-408 valve may be used.

A perspective view of the supply side 214 and return side 216 is shownin FIG. 10. As previously described, check valve 510 is located on thesupply side 214 before the supply side 214 forks into separate pipes. Onthe return side 216, the auto-vent valve 502 and ball valve 504 arelocated at the hi-point of the line. The TxP valve 506 and drain mayalso be located on the top part of the return side 216. A T-junction islocated on the return side 216 at an end of a pipe extending from themasonry heater 100. A first port of the T-junction is connected to thepipe extending from the masonry heater 100, and a second port at a 90degree angle from the first port is connected to piping on the returnside 216 of the system. At a third port of the T-junction, a sensorsheath housing a first temperature sensor 202 is inserted which shouldextend from the T-junction and into the coil pipe 200 within the masonryheater 100 to assure accurate temperature measurement of the liquid ator near its hottest point in the masonry heater 100.

FIG. 11 shows a sectional view of the return side 216 of the heattransfer apparatus. The TxP valve 506 and auto-vent valve 502 arelocated on a top portion of the return side 216. Piping extends in adirection orthogonal to the top portion to extend into the masonryheater 100. The T-junction is located on the bottom portion in FIG. 11,and the first port and third port extend coaxially, while the secondport extends in a direction orthogonal to the first and the third port.The liquid returning from the coil pipe 200 within the masonry heater100 travels through both the top portion and a lower portion, past theauto-vent valve 502, and to the masonry heater 100 and liquidcirculation pump 212.

Referring to FIG. 12, a threaded pipe is screwed into a fitting 1202,which is then inserted and bonded in the third port of the T-junction1200. A sensor sheath 1208 housing the first temperature sensor S1 isinserted in the first port of the T-junction 1200. The first temperaturesensor 202 should be located as close to the tip of the sensor sheath1208 as possible. A flush bushing 1204 is installed at the base of thesensor sheath 1208 to seal the T-junction 1200. The sensor sheath 1208should be long enough to extend through the wall of the masonry heater100 and into the firebox 104. When the liquid circulation pump 212 isoperating, liquid flows from the coil pipe 200 inside the masonry heater100 around the sensor sheath 1208 in a liquid return path of the coilpipe, and out of the second port of the T-junction 1200 toward theexternal heating device 208. In typical installations, the threadedpipe, the fitting, and the T-junction are 0.75 inches in diameter,whereas the sensor sheath 1208 is slightly smaller at about 0.5 inchesin diameter to allow flow of the liquid in the return path of the coilpipe.

FIG. 13 illustrates how the T-junction 1200, coil pipe 200, fitting1204, and sensor sheath 1208 appear in a sectional view on the returnside 216 when assembled. The coil pipe 200 extends from the fitting1204, through the wall of the masonry heater 100, and into the firebox104, where the coil pipe 200 winds back and forth to be exposed todirect heat and flames in the firebox 104. The sensor sheath 1208, whichhouses the first temperature sensor 202, extends from the first port ofthe T-junction 1200, through the T-junction 1200, and into the coil pipe200. The sensor sheath 1208 and the first temperature sensor 202 furtherextend through a wall of the masonry heater 100 and into the firebox104. In FIG. 13, a 12-inch sensor sheath is illustrated, which extendsthrough a 4.5 inch wall 106 of the masonry heater 100, and 3-4 inches ofthe sensor sheath extend into the firebox 104 so that the sensor S1 isexposed to liquid at or near its hottest point in the firebox 104.

Referring back to FIG. 4, sensor S1 (in the sensor sheath 1208) isconnected to an input of a controller 210. The controller 210 may be aJohnson Controls model A419ABC-1, by way of non-limiting example. Thecontroller 210 may be programmed to turn the liquid circulation pump 212on/off based on the temperature measured by the sensor S1 in the firebox104. When the controller 210 operates the liquid circulation pump 212 tocirculate the liquid, the controller 210 varies the flow rate of theliquid circulation pump 212 based on how much heat is transferred to theexternal heating device 208. Specifically and as described above, asensor S2 on the return side 216 of the coil pipes 200 measures thetemperature of the heated liquid being supplied to the external heatingdevice 208. Sensor S3 on the supply side 214 of the coil pipes 200measures the temperature of the heated liquid returning from theexternal heating device 208. The controller 210 determines a differencebetween the temperatures measured by the sensors S2 and S3, and adjuststhe flow rate of the liquid circulation pump 212 based on the measuredtemperature difference between sensors S2 and S3 to achieve a targettemperature difference. In one application described later, the targettemperature difference may be 20° F. The target temperature differenceis the amount of heat transferred from the masonry heater 100 to theexternal heating device 208. Placing the sensors S2 and S3 close to theoutput of the heat transfer apparatus, and close to the external heatingdevice 208, enables an accurate measurement of the heat actuallytransferred to the external heating device 208. On the other hand, ifthe sensors S2 and S3 were placed closer to the masonry heater 100, themeasured temperature difference would also measure the amount of heatlost in the piping between the masonry heater 100 and the externalheating device 208, leading to an inaccurate measurement of how muchheat is actually transferred to the external heating device 208.Although the liquid circulation pump 212 is disposed on the return side216 of the coil pipes 200 in FIG. 4, the liquid circulation pump 212 maybe placed on the supply side 214 of the coil pipes 200 without adverselyaffecting the performance of the heat transfer apparatus. In a poweroutage, the masonry heater 100 will continue to heat the liquid whilethe liquid circulation pump 212 cannot transfer heat. The TxP valve 506will prevent the liquid in the heat transfer apparatus from vaporizingand damaging the piping during a power outage. A battery back-up 218 maybe installed on the controller 210 and the liquid circulation pump 212to properly circulate the heated liquid and prevent the TxP valve 506from purging liquid from the system during a power outage. A batteryback-up 218 (not illustrated) may also be installed on the secondaryside of the external heating device 208 to allow the system to properlydump heat in the event of a power outage.

FIG. 14 illustrates the electrical connections of the controller 210.Sensor S1 is connected to input In1 of the controller 210, while sensorsS2 and S3 are connected to inputs In2 and In3, respectively, of thecontroller 210. The controller 210 reads a temperature from sensor S1and, based on whether the temperature is equal to or greater than apredetermined temperature threshold, controls whether the liquidcirculation pump 212 circulates liquid through the system. An output ofthe controller 210 is connected to the liquid circulation pump 212,either directly or through an intermediate device. The controller 210may be configured to output a digital HI/LO signal directing the liquidcirculation pump 212 to circulate liquid. Alternatively, the controller210 may be configured to generate an analog signal (e.g., 24V AC signalat 60 Hz) directing the liquid circulation pump 212 to circulate liquid.An intermediate device (not illustrated) may be used which generates aspecified analog signal when the HI/LO output of the controller 210outputs a HI digital signal. For example, the controller 210 may outputa +5V digital signal to a D/A converter, which outputs a 24V AC signalto the liquid circulation pump 212, causing the liquid circulation pump212 to circulate liquid through the system. These examples are intendedto be non-limiting descriptions of the myriad ways in which thecontroller 210 may control the liquid circulation pump 212.

The controller 210 may also determine the difference between the sensorsS2 and S3 and output a signal directing the liquid circulation pump 212to circulate liquid at a particular flow rate based on the measureddifference. Alternatively, sensors S2 and S3 may be connected directlyto the liquid circulation pump 212, which may be configured to controlthe flow rate based on the temperature difference measured betweensensors S2 and S3. The liquid circulation pump 212 may be a Tacovariable speed delta-T 00® circulator or a Taco HEC-2 BumbleBee®, by wayof non-limiting example.

Referring to FIG. 15, the external heating device 208 may be a boiler1500 in which a liquid is heated or vaporized. The controller 210 and/orliquid circulation pump 212 are configured to transfer a given amount ofheat to the boiler 1500 based on the heat required by the boiler 1500 tooperate.

Referring to FIG. 16A, the external heating device 208 may be a liquidheater 1600, such as a hot-water heater. The heated liquid from themasonry heater 100 is circulated into the liquid heater 1600, where theheated liquid flows over a plate heat exchanger 1602. The plate heatexchanger 1602 transfers heat from the heated liquid to a secondaryliquid, which may be water or glycol, for example. The secondary liquidmay be used as domestic heated water and may be used to provide radiantheat to a building. The radiant zone 1614 and associated devicesfunction as an over-heat thermal dump apparatus, which dumps heat fromthe masonry heater and liquid heater 1600 when the temperature of theheated liquid is too high. Because masonry heaters 100 generate verylarge amounts of heat, it is sometimes necessary to dump excess heatfrom the system to prevent vaporization of liquid in the system ordamage to the system. The radiant zone 1614 may be installed in a roomor several rooms to provide heat thereto. The radiant zone 1614 may alsobe installed in a cooler area of a building, such as a garage, whereheat may be more rapidly dumped than an interior room of a building. Theliquid heater 1600 in FIG. 16A may be an HTP Versa-Hydro CombinationHydronic Appliance, by way of non-limiting example.

Radiant heat zone 1614 radiates heat from heated liquid to an area in ahouse or building. Zone valve 1604 opens and closes to allow liquid toflow from the liquid heater 1600 to radiant zone 1614 when apredetermined control signal is received on control line V11. Liquidcirculation pump 1606 controls the flow rate of the liquid flowing fromthe liquid heater to the radiant zone 1614 based on the control signalreceived on control line V12. Although zone valve 1604 and liquidcirculation pump 1606 are both illustrated in FIG. 16A, it may benecessary to use only one or the other depending on the type of system.Temperature sensor S4 1608 measures the temperature T₄ of the liquid inthe liquid heater 1600. Temperature sensor S5 1610 and temperaturesensor S6 1612 measure the temperature of the liquid flowing to and fromthe radiant heat zone 1614, respectively. Temperature sensor S7 1613measures the ambient air temperature of the area in which the radiantheat zone 1614 is installed. Although only a single radiant heat zone1614 is illustrated in FIG. 16A, more than one radiant heat zone may beconnected to the liquid heater 1600 to selectively radiate heated liquiddistributed from liquid heater 1600. The radiant heat zones aretypically connected in parallel to the liquid heater 1600, but may beconnected in series depending on installation demands, such as thebuilding layout. A thermostat (not shown) controls each radiant heatzone.

FIG. 16B illustrates the control configuration of a single radiant heatzone. A user can set the temperature for the area corresponding to theradiant heat zone 1614 using control panel 1616. The thermostat 1618receives the desired temperature setting from the control panel 1616 andthe ambient air temperature measured by sensor S7. Thermostat 1618 mayread the temperature T₄ of the heated second liquid from the sensor S4in the liquid heater to better control the amount of heat radiated fromthe radiant heat zone 1614, although it is not necessary for thethermostat 1618 to monitor the sensor S4. Thermostat 1618 may alsomeasure the temperature differential (T₅−T₆) between sensors S5 and S6to measure the amount of heat actually radiated from the radiant heatzone 1614. Sensors S5 and S6 should be placed as close to the radiantheat zone 1614 to accurately measure the amount of heat actuallytransferred to and radiated from the radiant heat zone 1614. Thethermostat 1618 generates a control signal containing informationincluding whether the zone valve 1604 should be open or closed, and/orthe flow rate of the liquid circulation pump 1606 based on thetemperatures measured by sensors S4, S5, S6, and/or S7, as well as thedesired temperature setting from the control panel 1616. The controller1620 acts as a relay bypass to bypass the thermostat 1618 control whenthe temperature of the liquid in the liquid heater 1600 exceeds apredetermined temperature threshold. In this configuration, control ofthe radiant heat zones is achieved electrically, without the need todivert the heated liquid to a different channel or radiant zone. Thecontroller 1620 may be configured operate the zone valve 1604 and/orliquid circulation pump 1606 to dump heat between 160° F. and 180° F.,well-before the liquid is vaporized.

The controller 1620 outputs a zone valve control signal and/or acirculation pump control signal based on the control signal receivedfrom the thermostat 1618. The controller 1620 may be configured togenerate the zone valve control signal and/or the circulation pumpcontrol signal based on a control signal sent from the thermostat 1618,which includes the desired temperature setting and the temperaturemeasured by sensor S7 near the radiant heat zone 1614. When thecontroller 1620 determines that the temperature T₄ measured by sensor S4exceeds the predetermined temperature, the controller 1620 bypasses thecontrol signal sent from the thermostat and begins dumping heat from theliquid heater 1600 to the radiant heat zone 1614. That is, thecontroller 1620 enters a relay bypass mode in which heat is dumped fromthe liquid heater 1600 to the radiant heat zone to prevent thermalrunaway when the controller 1620 determines that the temperaturemeasured by sensor S4 exceeds the predetermined temperature. In therelay bypass mode, the controller 1620 controls the zone valve 1604and/or the liquid circulation pump 1606 independently of the thermostat1618 and the desired temperature setting until the radiant heat zone1614 dumps enough heat from the liquid heater 1600 to ensure that thesystem is not in danger of entering thermal runaway. The controller 1620may adjust the flow rate of the circulation pump 1606 based on thetemperature differential (T₅−T₆) of the temperatures measured by sensorsS5 and S6 to dump enough heat to efficiently and effectively reduce thetemperature of the heated liquid in the liquid heater. The controller1620 will continue to monitor the temperature T₄ measured by the sensorS4 and operate in the relay bypass mode until the temperature T₄measured by the sensor S4 is less than the predetermined temperature.Once the temperature T₄ returns to an acceptable level, the controller1620 returns to a normal operating mode wherein the controller outputs azone valve control signal and/or a circulation pump control signal basedon a control signal supplied by the thermostat 1618.

When multiple radiant heat zones 1614 are connected to the liquid heater1600, thermal dump control is separately performed for each zone. Thecontrol configuration for multiple radiant heat zones is illustrated inFIG. 16C. As previously discussed, the radiant heat zones are typicallyconnected in parallel to the liquid heater 1600, but may be connected inseries depending on the building in which the system is installed. Eachradiant heat zone may be a different size and therefore may each radiateand dump heat at different rates and may each comprise the elementsillustrated in FIG. 16A. Each radiant heat zone has a correspondingcontrol panel 1616-N and thermostat 1618-N, where N is an integerranging from 1 to the total number of radiant heat zones installed inthe system. A relay bypass RN1, RN2 is installed for each zone valve1604 and circulation pump 1606, respectively. The relay bypasses RN1,RN2 isolate the thermostats of each zone from one another. Relay bypassR11 has a first input connected to the Zone 1 ON/OFF signal ofthermostat 1618-1, a second input connected to the Zone 1 ON/OFF signalof controller 1620, and a third input connected to the Zone 1 Bypasssignal of controller 1620. Relay bypass R12 has a first input connectedto the Zone 1 flow rate signal of thermostat 1618-1, a second inputconnected to the Zone 1 flow rate signal of controller 1620, and a thirdinput connected to the Zone 1 Bypass signal of controller 1620. Everyrelay bypass RN1, RN2 is connected in a similar manner as R11 and R12,respectively.

When the controller 1620 determines that the temperature T₄ measured bysensor S4 exceeds the predetermined temperature, the controller selectsone or more of the radiant heat zones to bypass. The controller 1620 isconfigured to separately and selectively bypass the thermostat 1618-N ofeach zone and select which radiant heat zone to control. The controller1620 may select radiant heat zones based on the rate at which thetemperature T₄ measured by sensor S4 is increasing or the rate at whicheach zone is capable of dumping heat. The controller 1620 sends a relaybypass signal to the relay bypass RN1, RN2 of the selected zone(s),causing the selected relay bypass RN1, RN2 to output a signal from thecontroller 1620 instead of the corresponding thermostat 1618-N. Forexample, the relay bypasses R11 and R12 of zone 1 normally output thezone 1 ON/OFF signal and zone 1 flow rate signal, respectively, fromthermostat 1618-1. When the controller 1620 determines temperature T₄exceeds the predetermined temperature and selects zone 1 to bypass,controller 1620 outputs a bypass control signal to relay bypass R11 andR12, causing relay bypass R11 and R12 to output control signals from thecontroller 1620 instead of the thermostat 1618-1. The controller 1620may bypass and control the other thermal dump zones in a manner similarto zone 1.

Referring to FIG. 17, an over-heat thermal dump apparatus 1700 may beconnected to the heat transfer apparatus and heat transfer system todump excess heat from the system. In normal operation, the second liquidin the liquid heater 1600 is may be directed to a domestic liquid outlet1720, for example. As previously discussed, it is sometimes necessary todump excess heat from the system to prevent vaporization of liquid inthe system or damage to the system because masonry heaters 100 generatevery large amounts of heat. In the configuration shown in FIG. 17, thethermal dump apparatus 1700 is connected to the liquid heater 1600 andis equipped with a relay bypass 1702 to direct the heated secondaryliquid to a thermal dump zone (radiant heat zones 1706) where excessheat may be rapidly dumped. In this configuration, when the secondaryliquid in the liquid heater 1600 reaches a predetermined temperature, asmeasured by temperature sensor 1708 (S4), at which there is a danger ofthe secondary liquid being vaporized, the relay bypass 1702 isactivated, which transfers the heated second liquid to a radiant zone1706 to dump heat. The radiant zone 1706 may be coil heating pipesdistributed through the floor or walls of a building, efficiently usingthe excess heat in areas of a building that are remotely located awayfrom the masonry heater 100.

In normal operation, when the temperature of the second liquid is belowthe predetermined temperature, the second liquid flows from the liquidheater 1600 through the liquid circulation pump 1604, and directlythrough the relay bypass 1702. When the temperature of the second liquidexceeds the predetermined temperature, the controller 1704 operates therelay bypass 1702 to direct the second liquid toward the radiant heatzones 1706. The controller 1704 may be configured operate the relaybypass 1704 to dump heat between 160° F. and 180° F., well-before theliquid is vaporized. The radiant zone 1706 may be installed in a coolerarea of a building, such as a garage, where heat may be more rapidlydumped than an interior room of a building. The liquid heater 1600 inFIG. 17 may be an HTP Versa-Hydro Combination Hydronic Appliance, by wayof non-limiting example.

In FIG. 17, temperature sensors S4, S5 and S6 are located on a supplyside 1716 and return side 1718 of the relay bypass 1702 to measure thetemperature differential between sensors S5 and S6, which indicates anamount of heat being dumped to a radiant zone 1706. The heat measured onthe supply side 1716 by sensor 1710 (S5) should be higher than theambient air temperature, but much lower than the boiling point of thesecond liquid used. The liquid circulation pump 1714 controls the flowrate of the liquid in the radiant heat zones 1706 based on the measuredheat differential between sensors S4 and S5. The controller 1704 maydirect the liquid circulation pump 1722 to stop controlling the flow offluid in a thermal dump mode, allowing the liquid circulation pump 1714to control the flow rate. Alternatively, the controller 1714 may controlthe liquid circulation pump 1714 and liquid circulation pump 1722 inconcert. Once the temperature measured by the sensor S4 falls below thepredetermined temperature, the controller operates the relay bypass 1702to pass liquid directly to the domestic liquid outlet 1720 and directsthe liquid circulation pump 1714 to stop circulation of the secondliquid.

The flow rate is controlled to achieve an ideal amount of heat dumpedbased on the size of the radiant zones. For example, a 20° F.differential between sensors S5 and S6 may be selected, such that theflow rate is increased when the amount of heat dumped is greater than20° F., and the flow rate is decreased when the amount of heat dumped isless than 20° F. It is recommended to maintain the return side 1718 ofthe radiant zone at around 100° F., and the liquid in the supply side1716 so it does not exceed 140° F. to ensure that the system does notenter thermal runaway. Control of heat transfer to the thermal dumpzones is discussed in further detail later. Although the over-heatthermal dump control is described with reference to a liquid heater1600, the over-heat thermal dump control may be connected to any otherexternal heating device 208 to moderate temperature in the system. Thecontroller for the thermal dump control may be a Johnson ControlsA419GBF-1 (24 Volt DC), by way of non-limiting example. A singlecontroller may be used to control circulation of liquid within theliquid heater 1600, the thermal dump zones 1706, and in the coil pipes200.

FIG. 18 shows a configuration where the heated liquid from the masonryheater 100 is transferred to a duct coil 1800. The duct coil 1800 may beused in an HVAC system to distribute heat throughout a building viablown air.

Referring to FIG. 19, a low-loss header 1900 may be installed to providehydraulic isolation between the masonry heater 100 side of the heattransfer apparatus and heat transfer system. The low loss header 1900may be connected to one or more external heating devices 208, or may beconnected to radiant heating, as shown in FIG. 19. Another liquidcirculation pump 1902 may be connected to the secondary side of thelow-loss header 1900 to control the flow rate of liquid on the secondaryside relative to the primary side (i.e. the masonry heater 100 side).

Referring to FIG. 20, heated liquid from the masonry heater 100 may beported into the element ports of a hot water heater 2000, where theheated liquid from the masonry heater 100 may heat domestic water via aheat exchanger (not illustrated). The heated water from the hot-waterheater may then further be used in an oil heater 2002, such as aToyotomi oil miser, greatly increasing the efficiency of the oil heater.As previously discussed, a thermal dump apparatus 1700 may be installedon the liquid heater 2000 to dump heat when the heat of the liquid inthe liquid heater 2000 exceeds a predetermined temperature.

FIG. 21A illustrates a flow chart describing the functionality of thecontroller 210 and the liquid circulation pump. In step S100, thetemperature T₁ of sensor S1 in the coil pipe 200 within the masonryheater 100 is measured. If the temperature T₁ is less than a firstpredetermined temperature threshold (in step S102), the process proceedsback to step S1 where the temperature T₁ is measured again. If, on theother hand, the temperature T₁ is greater than or equal to a firstpredetermined temperature threshold (in step S102), the liquidcirculation pump is activated (S104), and the liquid circulation pumpbegins to circulate liquid in the system. As step S106, the temperatureT₁ is measured again, and if the temperature T₁ is less than the firstpredetermined temperature threshold at step S110, the first liquidcirculation pump is turned off in step S112 and the process begins againat step S100. If the temperature T₁ remains equal to or greater than thefirst predetermined temperature threshold, the process proceeds to stepS114. At step S122, the temperatures T₂ and T₃ of sensor S2 and sensorS3, respectively, are measured. At step S116, the difference (T₂−T₃) isdetermined, and if the difference (T₂−T₃) is greater than or equal to apredetermined temperature difference, the flow rate of the liquidcirculation pump is increased (step S122). When the temperature isgreater than the predetermined temperature difference, then too muchheat is being transferred to the external heating device 208, so theflow rate is increased to decrease the amount of heat transferred to theexternal heating device 208. If, in step S116, the difference (T₂−T₃) isless than the predetermined temperature difference, then the flow rateis decreased to increase the amount of heat transferred (S12).Alternatively, the flow rate may be kept constant if the difference(T₂−T₃) is within an acceptable predetermined range.

Referring to FIG. 21B, a process for dumping excess heat is illustratedusing the thermal dump apparatus illustrated in FIG. 17. In step S200,the temperature of sensor S1 is measured (in conjunction with theprocess discussed with respect to FIG. 21A), and when the temperatureexceeds the first predetermined temperature threshold, the processproceeds to step S204 to measure the temperature of the second liquid inthe liquid heater 1600. When the temperature of the liquid measured inthe external heating device 208 exceeds a third temperature threshold instep S206, the process proceeds to step S208, where a relay bypass 1702is operated to dump excess heat to radiant heating zones 1706. If thetemperature measured by sensor S4 is less than the third temperaturethreshold in step 206, the process returns to step S200.

After the relay bypass 1702 begins directing the second liquid to thethermal dump zones 1706, the temperature of the sensor S4 is againmeasured in step S210. In step S212, when the measured temperature ofthe second liquid falls below the third temperature threshold, the relaybypass 1702 directs the second liquid away from the thermal dump zones1706 and returns to the normal operation mode (step S214). When thetemperature T₄ measured by sensor S4 is greater than the thirdtemperature threshold, the liquid circulation pump 1714 circulates thesecond liquid to the thermal dump zones and the temperatures T₅ and T₆of the second fluid at sensors S5 and S6, respectively, are measured(step S216). At step 218 the difference (T₅−T₆) is determined, and whenthe difference (T₅−T₆) is within a predetermined temperature range (4thtemperature threshold), the liquid circulation pump 1714 maintains thecurrent flow rate. The heat of the liquid in the thermal dump zonesshould be maintained to 165° F.-170° F., such that (T₅−T₆) should beapproximately 5° F. It may be necessary to add more radiant heatingzones if the temperature in the radiant zones exceeds 180° F. to keepthe temperatures in the radiant zones comfortable. If the difference(T₅−T₆) exceeds the predetermined temperature range, the flow rate ofthe liquid transferred to the radiant heating zones is increased. If thedifference (T₅−T₆) is within the predetermined temperature range, theflow rate is maintained in step S220 (or decreased where necessary tomaintain an acceptable radiant temperature). Once enough heat is dumpedfrom the secondary side of the external heating device 208 such that thetemperature of the liquid in the external heating device 208 is lessthan the second temperature threshold, the relay bypass is turned offand the second liquid circulation pump stops pumping liquid to the dumpzones (S214).

Referring to FIG. 22, the previously-described heat transfer system mayadditionally include other heat sources to transfer heat to the externalheating device 2208, including a geothermal heat source 2210, a solarheat source 2204, and/or a backup heat source 2206. The solar heatsource 2204 may be a solar panel that generates electricity to power aheating element that heats the heat transfer liquid passing through areservoir or pipe connected to the heating element. The solar heatsource 2204 may be tubing or a container through which the heat transferliquid flows that passively absorbs heat from the sun. The backup heat2206 source may be a gas, oil or electric heat source that generatesheat when the other heat sources are not producing the desired amount ofheat. The geothermal heat source 2210 may be buried in the ground toabsorb heat directly from the earth, or may absorb heat directly fromthe air on a hot summer day. Other known heat sources may be connectedto the heat transfer system to achieve similar results.

The heat sources have a supply line and a return line each connected toclosely spaced T-junctions placed in series around a primary loop 2200.A liquid circulation pump 2202, 2212, 2224 is disposed on at least oneof the supply line and the return line of each of the heat sources totransfer heat by circulating a heat transfer liquid between the primaryloop 2200 and each of the heat sources. A liquid circulation pump 2216is also disposed in the primary loop 2200 to circulate the heat transferliquid in the primary loop 2200 and uniformly distribute the heattransfer liquid between the heat sources.

At least one other heat source is connected to the primary loop 2200 viaa supply line and a return line to receive heat from the primary loop2200. Although a liquid heater 1600 is illustrated in FIG. 22, theexternal heat device 2208 may be one or more of a boiler, a low-lossheader, or a duct coil, as previously described. In at least one of thesupply line and return line of the external heating device 2208, aliquid circulation pump 2218 is installed to transfer heat toward theexternal heating device 2208 by circulating liquid from the primary loop2200 to the external heating device 2208. A pump 2220 is installedbetween the liquid circulation pump 2218 and the external heating device2208. The portion of the system on the primary loop side is a primaryside while the portion of the system on the external heating device 2208side is a secondary side. The pump 2220 prevents flow on the primaryside from interfering with flow on the secondary side. On the secondaryside, a liquid circulation pump 2222 may be used to control flow on thesecondary side. As previously described, a plate heat exchanger 1602 inthe liquid heater 2208 transfers heat from the heat transfer liquid to asecond liquid. An over-heat thermal dump control, as discussed withrespect to FIG. 17, may be connected on the secondary side to dumpexcess heat from the secondary side.

Each of the liquid circulation pumps 2202, 2212, 2224 controls the flowof the heat transfer liquid in the primary loop 2200 to and from each ofthe respective heat sources. Sensors S2-S15 should be placed as close tothe T-junctions as possible to measure the heat transfer to the primaryloop from each of the heat sources. A primary circulation pump 2216 isdisposed in the primary loop to control flow of the heat transfer liquidaround the primary loop 2200. The primary circulation pump 2216 may beconnected to a controller 2214 that controls whether the primarycirculation pump 2216 circulates the heat transfer liquid around theprimary loop 2200, as well as the flow rate of the heat transfer liquidaround the primary loop 2200. The other liquid circulation pumps 212,2202, 2212, 2218, 2222, 2224 may be also connected to the controller2214 to control the amount of heat transferred to the external heatingdevice 2208. The controller 2214 may be preprogrammed to transfer aspecific amount of heat to the external heating device 2208 bycontrolling the primary circulation pump 2216 and other liquidcirculation pumps 212, 2202, 2212, 2218, 2222, 2224 in concert.Specifically, the controller controls whether each of the liquidcirculation pumps circulate liquid through the masonry heater 100 and/oreach of the other heat sources, as well as the flow rates of the liquidin the primary loop 2200 and/or the heat sources through which theliquid is flowing. The controller 2214 may also control the flow rate ofliquid on the secondary side and the thermal dump control on thesecondary side when necessary. When the masonry heater 100 is fired, itmay not be necessary to transfer heat from any of the other heat sourcesto the external heating device 208. In the summer, when the weather maybe too hot to fire the masonry heater 100, heat from the solar heatsource and geothermal heat source may be transferred to the externalheating device 2208 without circulating liquid to the masonry heater100. In this configuration, the heat transfer system may efficientlytransfer heat to one or several external heating devices 2208 yearround, greatly reducing the cost of heating.

While particular embodiments of the present invention have been shownand described, it will be obvious to those skilled in the art that,based upon the teachings herein, changes and modifications may be madewithout departing from this invention and its broader aspects and,therefore, the appended claims are to encompass within their scope allsuch changes and modifications as are within the true spirit and scopeof this invention. Furthermore, it is to be understood that theinvention is solely defined by the appended claims. It will beunderstood by those within the art that, in general, terms used herein,and especially in the appended claims (e.g., bodies of the appendedclaims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.).

It will be further understood by those within the art that if a specificnumber of an introduced claim recitation is intended, such an intentwill be explicitly recited in the claim, and in the absence of suchrecitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to inventions containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare statement of “two recitations,” without other modifiers,typically means at least two recitations, or two or more recitations).

1-28. (canceled)
 29. A heat transfer system comprising: a masonryheater; a coil pipe extending into a firebox of the masonry heaterthrough a first aperture in a wall of the firebox and exiting through asecond aperture in the wall of the firebox, the coil pipe winding backand forth in the firebox and being disposed so as to be exposed to firein the firebox, wherein a heat transfer liquid enters the coil pipe froma supply side of the coil pipe at the first aperture and the liquidexits the coil pipe from a return side of the coil pipe at the secondaperture; a first sensor disposed in a liquid return path on the returnside of the coil pipe, the first sensor extending into the coil pipewhere the coil pipe is directly exposed to heat within the firebox ofthe masonry heater, and the first sensor being configured to detect atemperature of the heat transfer liquid in the liquid return path, onthe return side of the coil pipe; a circulation pump configured totransfer the heat transfer liquid from the return path to an output ofthe coil pipe when the circulation pump is circulating the heat transferliquid in the coil pipe, and stopping transfer of the heat transferliquid to the output of the coil pipe when the circulation pump is notcirculating the heat transfer liquid in the coil pipe; and a controllerconfigured to control whether the circulation pump circulates the heattransfer liquid based on the temperature detected by the first sensor;and a heating device that absorbs heat from the heat transfer liquidtransferred from the masonry heater, the heating device being a liquidheater that heats a second liquid using the heat transferred from themasonry heater, the liquid heater comprising a plate heat exchanger,wherein the liquid transferred from the masonry heater heats the plateheat exchanger, and the plate heat exchanger heats the second liquid; asecond controller that controls flow of the liquid from an inside of theliquid heater to a heat dump zone outside of the liquid heater; and afourth sensor that detects a temperature of the second liquid in theliquid heater, wherein the second controller prevents the second liquidfrom flowing to the heat dump zone heater when the temperature of thesecond liquid in the heater is less than a third temperature, and thesecond controller allows the second liquid to flow to the heat dump zonewhen the temperature of the liquid in the liquid heater is greater thanthe third temperature.
 30. The heat transfer system according to claim29 further including: a fifth sensor that measures the temperature ofthe liquid flowing to the heat dump zone from the liquid heater; and asixth sensor that measures the temperature of the liquid flowing back tothe liquid heater from the heat dump zone, wherein the second controllercontrols a second flow rate of the liquid flowing to the heat dump zonebased on a second difference in temperature measured by the fifth sensorand the sixth sensor.
 31. The heat transfer system according to claim30, wherein: the second controller is configured to determine a secondtemperature difference between the temperatures measured by the fifthsensor and the sixth sensor, the second controller is configured toincrease a flow rate of the liquid to the heat dump zone when the secondtemperature difference is greater than a second temperature threshold,and the second controller is configured to decrease the flow rate of theliquid to the heat dump zone when the second temperature difference isless than the second temperature threshold.
 32. A heat transfer systemcomprising: a masonry heater; a coil pipe extending into a firebox ofthe masonry heater through a first aperture in a wall of the firebox andexiting through a second aperture in the wall of the firebox, the coilpipe winding back and forth in the firebox and being disposed so as tobe exposed to fire in the firebox, wherein a heat transfer liquid entersthe coil pipe from a supply side of the coil pipe at the first holeaperture and the liquid exits the coil pipe from a return side of thecoil pipe at the second hole aperture; a first sensor disposed in aliquid return path on the return side of the coil pipe, the first sensorextending into the coil pipe where the coil pipe is directly exposed toheat within the firebox of the masonry heater, and the first sensorbeing configured to detect the temperature of the heat transfer liquidin the liquid return path, on the return side of the coil pipe; acirculation pump configured to transfer the heat transfer liquid fromthe return path to an output of the heat transfer apparatus when thecirculation pump is circulating the heat transfer liquid in the coilpipe, and stopping transfer of the heat transfer liquid to the output ofthe heat transfer apparatus when the circulation pump is not circulatingthe heat transfer liquid in the coil pipe; a controller configured tocontrol whether the circulation pump circulates the heat transfer liquidbased on the temperature detected by the first sensor; and a heatingdevice that absorbs heat from the heat transfer liquid transferred fromthe masonry heater, the heating device being a duct coil that heats airin a heating duct using the liquid transferred from the masonry heater.33. A heat transfer system comprising: a masonry heater; a coil pipeextending into a firebox of the masonry heater through a first aperturein a wall of the firebox and exiting through a second aperture in thewall of the firebox, the coil pipe winding back and forth in the fireboxand being disposed so as to be exposed to fire in the firebox, wherein aheat transfer liquid enters the coil pipe from a supply side of the coilpipe at the first hole aperture and the liquid exits the coil pipe froma return side of the coil pipe at the second hole aperture; a firstsensor disposed in a liquid return path on the return side of the coilpipe, the first sensor extending into the coil pipe where the coil pipeis directly exposed to heat within the firebox of the masonry heater,and the first sensor being configured to detect the temperature of theheat transfer liquid in the liquid return path, on the return side ofthe coil pipe; a circulation pump configured to transfer the heattransfer liquid from the return path to an output of the heat transferapparatus when the circulation pump is circulating the heat transferliquid in the coil pipe, and stopping transfer of the heat transferliquid to the output of the heat transfer apparatus when the circulationpump is not circulating the heat transfer liquid in the coil pipe; and acontroller configured to control whether the circulation pump circulatesthe heat transfer liquid based on the temperature detected by the firstsensor; and a heating device that absorbs heat from the heat transferliquid transferred from the masonry heater, and wherein the heatingdevice is a low loss header.
 34. A heat transfer system comprising: amasonry heater; a coil pipe extending into a firebox of the masonryheater through a first aperture in a wall of the firebox and exitingthrough a second aperture in the wall of the firebox, the coil pipewinding back and forth in the firebox and being disposed so as to beexposed to fire in the firebox, wherein a heat transfer liquid entersthe coil pipe from a supply side of the coil pipe at the first holeaperture and the liquid exits the coil pipe from a return side of thecoil pipe at the second hole aperture; a first sensor disposed in aliquid return path on the return side of the coil pipe, the first sensorextending into the coil pipe where the coil pipe is directly exposed toheat within the firebox of the masonry heater, and the first sensorbeing configured to detect the temperature of the heat transfer liquidin the liquid return path, on the return side of the coil pipe; acirculation pump configured to transfer the heat transfer liquid fromthe return path to an output of the heat transfer apparatus when thecirculation pump is circulating the heat transfer liquid in the coilpipe, and stopping transfer of the heat transfer liquid to the output ofthe heat transfer apparatus when the circulation pump is not circulatingthe heat transfer liquid in the coil pipe; and a controller configuredto control whether the circulation pump circulates the heat transferliquid based on the temperature detected by the first sensor; and aheating device that absorbs heat from the heat transfer liquidtransferred from the masonry heater, the heating device being a liquidheater that heats a second liquid using the heat transferred from themasonry heater, the liquid heater comprising a plate heat exchanger,wherein the liquid transferred from the masonry heater heats the plateheat exchanger, and the plate heat exchanger heats the second liquid,and wherein the liquid heater further heats an oil heater.
 35. A heattransfer system comprising: a masonry heater; a coil pipe extending intoa firebox of the masonry heater through a first aperture in a wall ofthe firebox and exiting through a second aperture in the wall of thefirebox, the coil pipe winding back and forth in the firebox and beingdisposed so as to be exposed to fire in the firebox, wherein a heattransfer liquid enters the coil pipe from a supply side of the coil pipeat the first hole aperture and the liquid exits the coil pipe from areturn side of the coil pipe at the second hole aperture; a first sensordisposed in a liquid return path on the return side of the coil pipe,the first sensor extending into the coil pipe where the coil pipe isdirectly exposed to heat within the firebox of the masonry heater, andthe first sensor being configured to detect the temperature of the heattransfer liquid in the liquid return path, on the return side of thecoil pipe; a circulation pump configured to transfer the heat transferliquid from the return path to an output of the heat transfer apparatuswhen the circulation pump is circulating the heat transfer liquid in thecoil pipe, and stopping transfer of the heat transfer liquid to theoutput of the heat transfer apparatus when the circulation pump is notcirculating the heat transfer liquid in the coil pipe; a controllerconfigured to control whether the circulation pump circulates the heattransfer liquid based on the temperature detected by the first sensor;and a heating device that absorbs heat from the heat transfer liquidtransferred from the masonry heater; a circulation loop connected to theoutput of the heat transfer apparatus and the heating device; and asecondary heat source connected to the circulation loop configured totransfer heat to the circulation loop, wherein the controller isconfigured to control the flow of the heat transfer liquid around thecirculation loop and through the heat transfer apparatus, the secondaryheat source and the heating device.